Method of electroforming a component

Abstract

A method a forming a component by way of electrodeposition of a metallic layer over an exposed surface of a sacrificial mandrel, followed by forming a surface layer on the metallic layer, and heat treating the component. The heat treating includes a first heat treatment and a second heat treatment for forming a high-strength component.

What is claimed is: 
     
         1 . A method comprising:
 forming a component by way of electrodeposition of a metallic layer over an exposed surface of a sacrificial mandrel;   removing the sacrificial mandrel;   forming a surface layer of at least one alloying element on the metallic layer; and   heat treating the component having the metallic layer and the surface layer of at least one alloying element.   
     
     
         2 . The method of  claim 1 , wherein the metallic layer is one of elemental nickel, cobalt, iron, or nickel-cobalt alloy. 
     
     
         3 . The method of  claim 2 , wherein the at least one alloying element is selected from a group of: aluminum, silicon, tantalum, titanium, chromium, and boron. 
     
     
         4 . The method of  claim 3 , wherein the metallic layer has a thickness of 25 micrometers to 5000 micrometers. 
     
     
         5 . The method of  claim 4 , wherein the surface layer has a thickness of 12.5 micrometers to 130 micrometers. 
     
     
         6 . The method of  claim 3 , wherein the at least one alloying element comprises multiple alloying elements selected from the group. 
     
     
         7 . The method of  claim 6 , further comprising forming a second surface layer of at least one other alloying element and another heat treating of the component. 
     
     
         8 . The method of  claim 3 , wherein the metallic layer is elemental nickel and the at least one alloying element is aluminum and wherein the heat treating infiltrates the aluminum into the metallic layer and creates a strengthened precipitate of nickel-aluminide. 
     
     
         9 . The method of  claim 1 , wherein the heat treating comprises a first heat-treatment wherein the at least one alloying element infiltrates the metallic layer. 
     
     
         10 . The method of  claim 9 , wherein the heat treating comprises a second heat-treatment configured to form precipitates. 
     
     
         11 . The method of  claim 10 , wherein the second heat-treatment is a multi-step aging process. 
     
     
         12 . The method of  claim 9 , wherein the first heat-treatment is further configured to homogenize a distribution of the at least one alloying element. 
     
     
         13 . The method of  claim 1 , further comprising forming a second surface layer of at least one other alloying element and another heat treating of the component. 
     
     
         14 . The method of  claim 1 , wherein forming the surface layer comprises at least one of vapor phase x-iding or pack cementation. 
     
     
         15 . The method of  claim 1 , further comprising welding the metallic layer prior to forming the surface layer. 
     
     
         16 . The method of  claim 1 , wherein the heat treating is performed at a treatment temperature of 500° C. to 1200° C. 
     
     
         17 . The method of  claim 1 , wherein the component is a duct and wherein the surface layer is formed on an exterior surface and an interior surface of the duct. 
     
     
         18 . The method of  claim 17 , wherein the duct is at least one of non-linear, non-circular, or includes a variable metallic layer thickness. 
     
     
         19 . A component formed from the method of  claim 1 . 
     
     
         20 . The component of  claim 19 , wherein the metallic layer is elemental nickel, cobalt, iron, or a nickel-cobalt, or a nickel-cobalt-phosphorous alloy and the at least one alloying element is selected from a group of: aluminum, silicon, tantalum, titanium, chromium, and boron.